JP6951877B2 - How to connect the battery status detection sensor and the covered wire - Google Patents

Description

The present invention includes a battery status detection sensor and battery status detection that detect the current of a battery mounted on a vehicle such as an automobile and notify the battery status to an ECU (Engine Control Unit) that controls the engine. The present invention relates to a method of connecting a covered electric wire to a sensor.

Recently, for example, a battery status detection sensor that is interposed between a covered electric wire that connects a battery and an electrical component and the battery, detects the battery status based on the detected current, and notifies the ECU or the like has been proposed. Has been done.

For example, the battery state detection sensor described in Patent Document 1 includes a post terminal connected to a battery post of a battery, a shunt resistor connecting one coated electric wire via a stud bolt, and a post terminal and a shunt resistor. It is composed of a main body that detects and notifies the state of the battery by intervening between the two.

In this battery condition detection sensor, the coated electric wire and the battery condition detection sensor can be electrically connected by passing a connection terminal attached to the tip of the coated electric wire through a stud bolt and screwing it with a nut.

However, with the increase in electrical equipment in recent years, there is a demand to connect two coated wires to the Ciento resistor provided in the battery status detection sensor, but the two coated wires are combined with the stud bolt. Since the covered electric wire becomes bulky by connecting the wires, there is a problem that a space for that amount is required.

Japanese Unexamined Patent Publication No. 2011-21610

In view of the above problems, the present invention provides a battery state detection sensor capable of saving space in a state where two electric wires are securely connected, and a method for connecting a covered electric wire to the battery state detection sensor. With the goal.

The present invention, a post terminal attached to the battery post, is electrically connected to the post terminal, provided with a bus bar terminal having a shunt resistor, in the battery state detection sensor for measuring a characteristic of the battery, the bus bar terminal , Two coated electric wires formed in a plate shape and welded to the bus bar terminal are provided, and the coated electric wires are arranged on one main surface side of both main surfaces of the bus bar terminal formed in a plate shape. It is characterized in that it is composed of a first-coated electric wire that has been welded and welded, and a second-coated electric wire that is arranged and welded on the other main surface side of the bus bar terminal formed in a plate shape. do.

Further, the present invention is provided with a post terminal attached to a battery post and a bus bar terminal electrically connected to the post terminal and having a shunt resistance, and the bus bar terminal in a battery state detection sensor for measuring battery characteristics is provided. A method of connecting a coated electric wire for connecting a coated electric wire, wherein the bus bar terminal is formed in a plate shape, and one of the two coated electric wires is formed in a plate shape. It is arranged on one of the main surfaces of both main surfaces, welded to the one main surface, and the other covered electric wire is arranged on the other main surface side of the plate-shaped bus bar terminal. , The other main surface is welded.

The above-mentioned welding includes the case where the coated electric wire and the bus bar terminal are welded regardless of the welding method, for example, by ultrasonic welding, resistance welding, laser welding, arc welding, or the like.
The coated electric wire refers to an electric wire in which a conductive wire is coated with an insulating coating, and the conductor includes a wire made of a conductive material such as aluminum, copper, or an aluminum alloy.

According to the present invention, it is possible to save space while the two electric wires are securely connected.
More specifically, since the coated electric wire is connected to both main surfaces of the bus bar, the space occupied by the coated electric wire with respect to both main surfaces can be suppressed to the space occupied by one coated electric wire. As a result, the space occupied by the coated electric wire can be reduced as compared with the case where two coated electric wires are connected to the main surface on one side, for example.

Further, by welding the coated electric wire to the bus bar terminal, the space occupied by the other member can be deleted as compared with the case of fixing with the other member. Therefore, while reducing the space occupied by the coated electric wire, the said The bus bar terminal and the covered electric wire can be electrically connected.

More specifically, for example, when two covered electric wires are connected to the bus bar terminal having a main surface in the vertical direction, that is, the first coated electric wire is on the upper surface which is one main surface of the bus bar terminal. When welded and the second coated wire is welded to the lower surface which is the other main surface of the bus bar terminal, the second coated wire is the bus bar terminal arranged at a predetermined position, that is, in the height direction. It will be arranged on the lower side with respect to the bus bar terminal whose position is fixed. Therefore, as compared with the case where two covered electric wires are connected to the upper side of the bus bar terminal, only one covered electric wire is connected to the upper side of the bus bar terminal, and the upper side of the bus bar terminal The space occupied by the covered electric wire can be suppressed.

Further, since the coated electric wire is welded to the upper surface of the bus bar terminal, it is not necessary to arrange a fixing member such as a stud bolt or a nut for screwing on the upper side of the bus bar terminal. While saving space on the upper side, the bus bar terminal and the covered electric wire can be reliably electrically connected.

As described above, according to the present invention, the space occupied by the covered electric wire can be reduced on one side of the bus bar terminal arranged at a predetermined position, and the bus bar terminal and the coated electric wire can be electrically connected.

As an aspect of the present invention, the bus bar terminal is arranged so that one main surface is on the tip end side of the battery post and the other main surface is on the base end side of the battery post. However, it may be a small diameter coated electric wire having a smaller diameter than the second coated electric wire.

According to the present invention, the space occupied by the coated electric wire on one side of the bus bar terminal can be surely reduced, and it can be easily confirmed that two covered electric wires are connected to the bus bar.

More specifically, the first coated electric wire connected to the main surface on one side has a smaller diameter than the second coated electric wire connected to the main surface on the other side, and therefore is arranged at a predetermined position. The first coated electric wire having a small diameter can be arranged on one side of the bus bar terminal, and the space occupied by the coated electric wire on one side of the bus bar terminal can be more reliably reduced.

Further, since the first coated electric wire has a smaller diameter than the second coated electric wire, when the connection state of the coated electric wire is confirmed from the one side, the first coated electric wire having a smaller diameter is the other. It is not hidden by the second coated electric wire, and it is easy to visually recognize that the two coated electric wires are connected.

Further, as an aspect of the present invention, the two covered electric wires may be arranged along the longitudinal direction of the bus bar terminal.
According to the present invention, the first-coated electric wire and the second-coated electric wire can be easily wrapped with, for example, a binding band or tape, and can be easily packed, for example, when being transported.

Further, as an aspect of the present invention, the coated electric wire is exposed from the stranded conductor, the insulating coating covering the stranded conductor, and the tip of the insulating coating among the stranded conductors, and is welded to the tip welding process. The tip welded portion may be welded to the bus bar terminal.

According to the present invention, the conductors constituting the twisted wire conductor can be welded to each other in the tip welded portion, and the twisted wire conductor and the bus bar terminal can be welded so as to be conductive. Therefore, the twisted wire conductor and the bus bar terminal can be welded to each other. And the conductivity between the stranded conductors can be improved.

Further, as an aspect of the present invention, the tip welded portion may be welded to a width corresponding to the width of the bus bar terminal.
The welding process includes, for example, welding using a brazing material, thermal resistance welding, spot welding, laser welding, fusing in which a metal or the like is wound around the conductor portion and heat is applied to crimp it. ..

According to the present invention, since the tip conductive portion to be arranged with respect to the bus bar terminal can be reliably positioned, the contact area between the bus bar terminal and the tip conductive portion can be secured as a desired contact area, and the contact area can be reliably secured. Conductivity can be improved.

Further, as an aspect of the present invention, the coated electric wire is an eccentric coated electric wire in which the tip welded portion is eccentric from the axial direction of the coated electric wire and welded, and the eccentric coated electric wire has two coatings. The wires may be arranged so as to separate them from each other.

According to the present invention, it is possible to prevent the first-coated electric wire and the second-coated electric wire from interfering with each other. Thereby, for example, it is possible to prevent the first coated electric wire from being pushed up to one side by the second coated electric wire. Therefore, it is possible to prevent the space occupied by the covered electric wire connected to the main surface of the one side from increasing on the one side of the bus bar terminal.

Further, as an aspect of the present invention, a brazing material may be provided at a welded portion where the coated electric wire is welded at the bus bar terminal.
According to the present invention, since the coated electric wire and the bus bar terminal can be reliably welded, the conductivity between the coated electric wire and the bus bar terminal can be more reliably improved. The brazing material may be any material as long as the bus bar terminal and the coated electric wire can be welded, and includes phosphorus copper brazing, aluminum brazing, silver brazing, and the like.

INDUSTRIAL APPLICABILITY According to the present invention, it is possible to provide a battery state detection sensor capable of saving space in a state where two electric wires are securely connected, and a method of connecting a covered electric wire to the battery state detection sensor.

Schematic perspective view of the battery status detection sensor assembled to the battery. Schematic plan view of the battery status detection sensor. A cross-sectional view taken along the line AA of the battery state detection sensor. Flowchart of connection method of covered electric wire. Flow chart of electric wire processing process. Flowchart of connection process. Explanatory drawing of the method of attaching a brazing material to a bus bar terminal. Flow chart of the pre-process. Explanatory drawing explaining the method of attaching a brazing material to a bus bar terminal. Explanatory drawing of arrangement method of covered electric wire with respect to bus bar terminal. Explanatory drawing of connection method of bus bar terminal and covered electric wire. Schematic perspective view of the battery status detection sensor at the time of packing.

An embodiment of the present invention will be described below with reference to the drawings.
FIG. 1 shows a schematic perspective view of the battery state detection device 1 assembled to the battery 100, FIG. 2 shows a schematic plan view of the battery state detection device 1, and FIG. 3 is an arrow view of AA in FIG. A cross-sectional view is shown.
FIG. 4 shows a flowchart of a method of connecting a covered electric wire, FIG. 5 shows a flowchart of an electric wire processing process, and FIG. 6 shows a flowchart of a connecting process.

FIG. 7 shows an explanatory view for explaining the processing method of the first coated electric wire 40, FIG. 8 shows a flowchart of the preliminary process, and FIG. 9 shows a method for attaching the phosphorus copper brazing 60 to the bus bar terminal tip portion 32. FIG. 10 shows an explanatory diagram illustrating a method of arranging the first coated electric wire 40 and the second coated electric wire 50 with respect to the bus bar terminal tip portion 32, and FIG. 11 shows the bus bar terminal tip portion 32, the first coated electric wire 40, and the first coated electric wire 40. The explanatory drawing explaining the connection method of the 2nd coated electric wire 50 is shown. Then, FIG. 12 shows a schematic perspective view of the battery state detection device 1 at the time of packing.

Further, in the drawing, the arrow X indicates the front-rear direction (hereinafter referred to as “front-back direction X”), and the arrow Y indicates the width direction (hereinafter referred to as “width direction Y”). In the front-rear direction X, the shunt resistor 30 side (lower left side in FIG. 1) of the battery state detection device 1 described later is the front, and the opposite direction (upper right side in FIG. 1) is the rear. In addition, in the figure, the arrow Z indicates the vertical direction (hereinafter referred to as "vertical direction Z"), the upper side in FIG. 1 is upward, and the lower side is downward.

The battery state detection device 1 is interposed between a battery 100 mounted on a vehicle such as an automobile and a covered electric wire (not shown) that energizes the battery, and detects the state of the battery 100 based on the detected current or the like. It also has a function of notifying an ECU (not shown) that controls the engine.

Specifically, as shown in FIG. 1, the battery state detection device 1 includes a battery state detection device main body 2 that can be connected to a battery post 101 provided in the battery 100, and a bus bar terminal tip portion that constitutes the battery state detection device main body 2. It is composed of a first coated electric wire 40 and a second coated electric wire 50 connected to 32.

The battery state detection device main body 2 includes a connection terminal 10 connected to one of the battery posts 101 in the battery 100, a detection device main body 20 that is interposed between the connection terminal 10 and the shunt resistor 30 to detect the characteristics of the battery. It is composed of a shunt resistor 30 that allows the connection of the first coated electric wire 40 and the second coated electric wire 50.

The connection terminal 10 is integrally composed of a terminal main body 11 connected to the battery post 101 arranged at the negative pole and a terminal connecting body 12 extending from the terminal main body 11 and connected to the detection device main body 20. ..

As shown in FIG. 3, the detection device main body 20 is a hollow resin housing containing a circuit board 21 and two conductive board connection terminals 22, and includes the circuit board 21 and the board connection terminals 22. It is composed of a storage unit 20d for storing the storage unit and a main body cover 20u for covering the upper part of the storage unit 20d.

As shown in FIG. 3, the circuit board 21 forms an electric circuit pattern (not shown) on the plate surface of a substantially plate-shaped insulating plate having an insulating property, and has a plurality of openings that can be connected to the electric circuit pattern. A CPU (not shown) and a memory (not shown) are mounted by forming a shape having a through hole.

As shown in FIGS. 1 to 3, the shunt resistor 30 connected to the detection device main body 20 has a shunt resistor 31 and a rectangular bus bar terminal tip portion provided on one end side (front side) of the shunt resistor 31. It is a terminal member provided with 32, and is connected to the back side of the detection device main body 20 and a shunt resistor 31 is used to measure the current of the battery 100.

One end side of the bus bar terminal tip portion 32 is made of a copper alloy having a width L in the width direction Y and a thickness of about 1 mm, a first coated electric wire 40 on the upper surface 33, and a first coated electric wire 40 on the bottom surface 34. The second coated electric wire 50 is welded. A welded portion 35 integrally formed is formed at the welded portion of the bus bar terminal tip portion 32 and the first coated electric wire 40 and the second coated electric wire 50.

As shown in FIGS. 1 to 3, the first coated electric wire 40 and the second coated electric wire 50 are arranged so that the longitudinal direction coincides with the longitudinal direction (front-rear direction X) of the bus bar terminal tip portion 32.
The coated electric wires 40 and 50 have a structure in which stranded conductors 41 and 51 having a substantially circular cross section formed by twisting aluminum strands are coated with insulating insulating coatings 42 and 52, and the tip side (the tip side ( The rear side) is provided with tip welded portions 43 and 53 in which the insulating coatings 42 and 52 are cut out and the stranded conductors 41 and 51 are exposed. The tip welded portions 43 and 53 are processed so as to have a flat plate shape substantially equal to the width L, and the stranded wires are connected to each other by welding.

In the present embodiment, the stranded conductors 41 and 51 are made of aluminum, but they do not necessarily have to be made of aluminum, and any material may be used as long as it is conductive and can be welded. For example, it is made of copper. It may be made of a stranded conductor, an aluminum alloy, a copper alloy, or the like. Further, the stranded conductor 41 and the stranded conductor 51 may be made of different conductive materials.
Further, the diameters of the first coated electric wire 40 and the second coated electric wire 50 may be the same, or the first coated electric wire 40 may be thicker than the second coated electric wire.

The battery state detection device 1 having such a configuration has a configuration in which the coated electric wires 40 and 50 are welded to the bus bar terminal tip portion 32 constituting the shunt resistor 30. Since the second tip welded portion 53 provided at the tip of the second coated electric wire 50 and the insulating coating 52 are configured so that their axes are eccentric, the first coated electric wire connected to the bus bar terminal tip 32 is connected. The axial directions of the 40 and the second coated electric wire 50 are separated from each other (see FIG. 3).

Further, as will be described later, since the coated electric wires 40 and 50 and the bus bar terminal tip portion 32 are integrally formed by being welded via a phosphorus copper brazing 60, the first coated electric wire 40 and the second coated electric wire 50 and the bus bar are integrally formed. A layer of phosphorus copper brazing 60 is formed between the terminal tip portion 32 and the terminal tip portion 32 (see the enlarged view in FIG. 1).

Next, a welding method for welding the first coated electric wire 40 and the second coated electric wire 50 to the bus bar terminal tip portion 32 provided in the battery state detection device main body 2 will be described with reference to FIGS. 4 to 11.
Here, the battery state detection device main body 2 welds the substrate connection terminal 22 and the connection terminal 10 to the shunt resistor 30, and insert-molds the storage portion 20d to form a hollow housing to connect the substrate. After assembling the circuit board 21 to the terminal 22, it is formed by closing the upper part of the storage portion 20d with the main body cover 20u. Then, after inspecting the battery state detection device main body 2, the first coated electric wire 40 and the second coated electric wire 50 are welded to the bus bar terminal tip portion 32 provided in the shunt resistor 30.

As shown in FIG. 4, the welding method of welding the first coated electric wire 40 and the second coated electric wire 50 to the tip portion 32 of the bus bar terminal is an electric wire processing step of processing the first coated electric wire 40 and the second coated electric wire 50. The connection step s2 for connecting the s1 and the processed first coated electric wire 40 and the second coated electric wire 50 to the bus bar terminal tip portion 32 is performed in order.

As shown in FIG. 5, the electric wire processing step s1 includes a tip processing step t1 for processing the tip portions of the stranded conductor 41 and the stranded conductor 51 into a flat plate shape, and the stranded wire conductor 41 and the stranded wire processed into a flat plate shape. It is composed of a tip welding step t2 for welding the tip portion of the conductor 51.

On the other hand, in the connection step s2, as shown in FIG. 6, the arrangement step u1 in which the first tip welded portion 43 and the second tip welded portion 53 are arranged on the upper surface 33 and the bottom surface 34, respectively, and the bus bar terminal tip portion 32 It is composed of an electric wire welding step u2 for welding the first tip welding processed portion 43 and the second tip welding processed portion 53 arranged in.

First, the tip processing step t1 will be described with reference to FIG.
Here, FIG. 7 is an explanatory view of an electric wire processing process for processing the tip portion of the first coated electric wire 40 before welding to the tip portion 32 of the bus bar terminal, and FIG. 7A is an explanatory view of the first coated electric wire 40 before processing. 7 (b) shows a schematic plan view and a schematic side sectional view of the tip processing step t1 for processing the tip portion of the first coated electric wire 40, and FIG. 7 (b) shows a schematic plan view and a schematic side sectional view of the above. c) shows a schematic plan view and a schematic side sectional view of the tip welding step t2 for welding the tip portion of the processed first coated electric wire 40. Since the electric wire processing step s1 of the second coated electric wire 50 is also performed in the same procedure, the illustration and description will be omitted.

First, as a preliminary step, the insulating coating 42 that covers the tip portion of the stranded conductor 41 formed in a circular cross section is cut out by a desired length, and the first tip exposed portion 43a, which is the tip portion of the stranded conductor 41. (See FIG. 7 (a)).

Further, as a preliminary step, at least one of the stranded conductor 41 and the stranded conductor 51 exposed so as to be eccentric from the center of the first coated electric wire 40 and the second coated electric wire 50 is bent to form a first tip welded portion. An eccentric step is performed in which the axial direction of the 43 and the second tip welded portion 53 and the axial direction of the first coated electric wire 40 and the second coated electric wire 50 are eccentric, respectively.

In the present embodiment, the stranded conductor 51 is exposed for a long time from the tip side of the second coated electric wire 50, and the second tip exposed portion 53a is second coated before the second tip exposed portion 53a is processed into a flat plate shape. An eccentric step of bending the electric wire 50 so as to be eccentric from the center is performed. Since this eccentric step is a preliminary step, a coated electric wire that has been eccentric in advance may be prepared, or may be performed after the tip processing step t1 and the tip welding step t2.

Next, as shown in FIG. 7B, the exposed first tip exposed portion 43a is arranged in the compressor 200 and compressed from the vertical direction to obtain the first tip exposed portion 43a having a width L. It is processed into a flat plate (tip processing step t1).

Then, as shown in FIG. 7C, a current is passed through the welding device 300 to the first exposed portion 43a processed on the flat plate to heat the first exposed portion 43a, and the first tip exposed portion 43a is sufficiently heated. By bringing the brazing member 310 made of phosphorous copper brazing 60 into contact with the first exposed tip portion 43a and melting it, the first tip exposed portion 43a is impregnated with the phosphorous copper brazing 60, and the first tip exposed portion is exposed. The conductors constituting 43a are welded together (tip welding step t2). As a result, the first tip welded portion 43 can be formed at the tip portion of the first coated electric wire 40.

The tip welded portions 43 and 53, which are processed into a flat plate shape in this way, are welded because the strands constituting the stranded conductors 41 and 51 are electrically connected to each other by welding. Conductivity is improved compared to the case without it.

Next, the connection step s2 for connecting the coated electric wires 40 and 50 thus processed to the bus bar terminal tip portion 32 will be briefly described with reference to FIGS. 8 to 11.
Here, FIG. 9 (a) shows a schematic side sectional view before mounting the phosphor copper wax 60 on the bus bar terminal tip 32, and FIG. 9 (b) shows a phosphor copper wax on the bus bar terminal tip 32. A schematic side sectional view when the 60 is attached is shown, and FIG. 9 (c) shows a schematic side sectional view of the bus bar terminal tip portion 32 to which the phosphorus copper wax 60 is attached.

FIG. 10 shows an explanatory diagram for explaining an arrangement step u1 in which the first coated electric wire 40 and the second coated electric wire 50 are arranged on the phosphorus copper brazing 60, and FIG. 10A shows the first coated electric wire 40 and the first coated electric wire 40. 2 A schematic plan view of a state in which the coated electric wire 50 is arranged on the phosphorus copper brazing 60 is shown, and FIG. A side sectional view is shown. FIG. 11 shows a schematic side sectional view showing a state in which the first coated electric wire 40 and the second coated electric wire 50 are welded by ultrasonic welding while being arranged on the phosphorus copper brazing 60.

First, the brazing material mounting performed as a preliminary step of mounting the phosphorus copper brazing 60 on the bus bar terminal tip portion 32 in advance will be described with reference to FIG.
As shown in FIG. 9, the brazing material is attached by crimping the phosphorus copper brazing 60 to the upper surface 33 and the bottom surface 34 of the bus bar terminal tip portion 32.

Specifically, as shown in FIG. 8, the mounting step v1 in which the phosphorus copper brazing 60 is mounted on the crimping surfaces of the two crimping machines 400 facing in the vertical direction, and the tip of the bus bar terminal at a position corresponding to the phosphorus copper brazing 60. A crimping step v2 for arranging the portions 32 (see FIG. 9A) and a crimping step v3 for crimping by moving the crimping machines 400 facing each other in the vertical direction Z toward the tip portion 32 of the bus bar terminal (FIG. 9 (b)). ) And). As a result, the phosphorus copper wax 60 is spread over a predetermined range and mounted on the bus bar terminal tip portion 32 (see FIG. 9C).

In the present embodiment, the basba terminal tip 32b formed in a flat plate shape is crimped from the vertical direction Z with a crimping machine 400 to which the phosphocopper brazing 60 is mounted so that the phosphocopper brazing 60 is mounted on the bus bar terminal tip 32b. However, for example, a recess of a desired size is provided at a place where the first tip welded portion 43 and the second tip welded portion 53 are arranged, a phosphorus copper brazing 60 is arranged at that position, and the crimping machine 400 moves up and down. The bus bar terminal tip 32 may be crimped from the direction Z.

Further, the phosphorus copper brazing 60 is attached to the crimping machine 400, and the bus bar terminal tip 32 is crimped from the vertical direction by the crimping machine 400, so that the phosphor copper wax 60 is attached to the bus bar terminal tip 32. The phosphorous copper brazing 60 may be attached to the upper surface 33 and the bottom surface 34 of the bus bar terminal tip portion 32 in advance, and then the phosphorous copper brazing 60 may be crimped to the bus bar terminal tip portion 32 by the crimping machine 400.
The method of mounting the phosphorus copper wax 60 is not limited to the above, and any method may be used as long as the phosphorus copper wax 60 can be mounted on the bus bar terminal tip portion 32.

Further, the brazing material for mounting the phosphorus copper brazing 60 on the bus bar terminal tip 32 may be mounted on the shunt resistor 30 before welding the board connecting terminal 22 or the like, or the board connecting terminal 22 or the like. May be done after welding. That is, it may be performed at any time before connecting the first coated electric wire 40 and the second coated electric wire 50.

A first coated electric wire 40 having a first tip welded portion 43 welded to the upper surface 33 of the bus bar terminal tip portion 32 to which the phosphorus copper brazing 60 is crimped is provided on the bottom surface 34. On the other hand, the second coated electric wire 50 having the second tip welded portion 53 is arranged. At this time, the widths of the first tip welded portion 43 and the second tip welded portion 53 have the same width L as the width of the bus bar terminal tip portion 32, so that positioning is easy and the width of the bus bar terminal tip portion 32 is adjusted. In addition, the first tip welded portion 43 and the second tip welded portion 53 can be arranged (see FIG. 10A).

Further, the second coated electric wire 50 eccentric from the center of the insulating coating 52 has the second tip welded portion 53 on the bottom surface so that the insulating coating 52 is arranged on the lower side with respect to the second tip welded portion 53. It is arranged at 34 (see FIG. 10B). That is, the axial direction of the second coated electric wire 50 is arranged so as to be separated from the axial direction of the first coated electric wire 40.

As shown in FIG. 11, ultrasonic waves are applied from the ultrasonic welding machine 500 to the first tip welded portion 43 and the second tip welded portion 53 appropriately arranged on the upper surface 33 and the bottom surface 34. By irradiating from the vertical direction at the same time, the phosphorus copper wax 60 attached to the bus bar terminal tip 32 is heated and melted, so that the first tip welded portion 43 and the second tip welded portion 53 are heated and melted. Welded to form the welded portion 35 (wire welding step u2).
From this, it is possible to manufacture the battery state detection device main body 2 in which the first coated electric wire 40 and the second coated electric wire 50 are welded and connected to the tip end portion 32 of the bus bar terminal.

The battery state detection device main body 2 configured in this way is provided with a connection terminal 10 attached to the battery post 101 and a shunt resistor 30 electrically connected to the connection terminal 10 and having a shunt resistance 31. The first coated electric wire 40 and the second coated electric wire 50 welded to the bus bar terminal tip portion 32 constituting the resistor 30 are provided, and the first coated electric wire 40 is provided on the upper surface 33 of the main surface of the bus bar terminal tip portion 32. The second coated electric wire 50 is arranged and welded, and the second coated electric wire 50 is arranged and welded on the bottom surface 34 of the main surface of the bus bar terminal tip portion 32, so that the first coated electric wire 40 and the second coated electric wire 50 With the 50s securely connected, it is possible to save space on the upper side of the bus bar terminal tip portion 32.

More specifically, in order to connect the first coated electric wire 40 and the second coated electric wire 50 to the upper surface 33 and the bottom surface 34, which are both main surfaces of the bus bar terminal tip portion 32, respectively, the coated electric wire is on the upper side of the shunt resistor 30. Since only the first coated electric wire 40 arranged on the upper surface 33 side occupies the space occupied by the covered electric wire, the space occupied by the coated electric wire can be suppressed. Thereby, for example, the space occupied by the coated electric wire can be reduced as compared with the case where the first coated electric wire 40 and the second coated electric wire 50 are connected to the upper surface 33 which is the main surface on one side.

Further, by welding the first coated electric wire 40 and the second coated electric wire 50 to the tip portion 32 of the bus bar terminal, the space occupied by the other member is compared with the case where the first coated electric wire 40 and the second coated electric wire 50 are fixed by another member such as a bolt. Can be removed and does not require space occupied by other members on the upper side of the shunt resistor 30. Further, by welding the first coated electric wire 40 and the second coated electric wire 50 to the tip portion 32 of the bus bar terminal, the first coated electric wire 40 and the second coated electric wire 50 can be reliably electrically connected to the shunt resistor 30. ..

More specifically, as shown in FIGS. 1 to 3, the battery state detection device main body 2 has an upper surface of a bus bar terminal tip portion 32 in which the first coated electric wire 40 and the second coated electric wire 50 have a main surface in the vertical direction Z. The structure is welded to 33 and the bottom surface 34, respectively.

As described above, the second coated electric wire 50 is arranged below the shunt resistor 30 arranged at a predetermined position, that is, the bus bar terminal tip portion 32 in which the position in the vertical direction Z is fixed. Therefore, the height occupied by the coated electric wire on the upper side can be suppressed as compared with the case where the first coated electric wire 40 and the second coated electric wire 50 are connected to the upper surface 33.

Further, since the first coated electric wire 40 is welded to the upper surface 33, it is not necessary to arrange a fixing member such as a stud bolt or a nut for screwing on the upper side of the bus bar terminal tip portion 32, and the bus bar terminal tip portion 32 The space on the upper side can be saved, and the shunt resistor 30 and the first coated electric wire 40 can be electrically connected.
Further, since a fixing member for fixing the first coated electric wire 40 to the bus bar terminal tip portion 32 is not required, the cost can be reduced.

In this way, the battery state detection device main body 2 has a shunt resistor 30 as compared with the case where two covered electric wires are connected to the upper side of the shunt resistor 30 (bus bar terminal tip portion 32) arranged at a predetermined position. The space occupied by the coated electric wire on the upper side of (the tip end portion 32 of the bus bar terminal) can be reduced, and the first coated electric wire 40 and the second coated electric wire 50 can be electrically connected to the shunt resistor 30.

Further, the bus bar terminal tip portion 32 is arranged so that the upper surface 33 is on the tip end side of the battery post 101, that is, the upper side, and the bottom surface 34 is on the base end side, that is, the lower side of the battery post 101, and is welded to the upper surface 33. The first coated electric wire 40 is composed of a small-diameter coated electric wire having a smaller diameter than the second coated electric wire 50 welded to the bottom surface 34, so that the space occupied by the coated electric wire on the upper side of the bus bar terminal tip portion 32 is occupied. It can be surely reduced, and it can be easily confirmed that two of the first coated electric wire 40 and the second coated electric wire 50 are connected to the bus bar terminal tip portion 32.

More specifically, since the first coated electric wire 40 connected to the upper surface 33, which is the main surface on the upper side, has a smaller diameter than the second coated electric wire 50 connected to the bottom surface 34, which is the main surface on the lower side. The first coated electric wire 40 having a small diameter is arranged on the upper side with respect to the bus bar terminal tip portion 32 arranged at a predetermined position (height). Therefore, the space occupied by the covered electric wire on the upper side of the shunt resistor 30 can be reduced more reliably.

Further, since the first coated electric wire 40 has a smaller diameter than the second coated electric wire 50, when the connection state of the first coated electric wire 40 and the second coated electric wire 50 is confirmed from the upper side, the first coated electric wire 40 Is not hidden by the second coated electric wire 50, so that it is easy to visually recognize that the first coated electric wire 40 and the second coated electric wire 50 are connected.

Further, the first coated electric wire 40 and the second coated electric wire 50 are arranged and welded along the front-rear direction X, which is the longitudinal direction of the bus bar terminal tip portion 32, and thus are the main surfaces on the upper side. The first coated electric wire 40 connected to the upper surface 33 and the second coated electric wire 50 connected to the lower surface 34, which is the main surface on the lower side, can be wound together with a tape 70 (see FIG. 12). This facilitates packaging, for example, when transporting.

Further, the coated electric wires 40 and 50 are composed of the stranded conductors 41 and 51 and the insulating coatings 42 and 52 covering the stranded conductors 41 and 51, and the insulating coating 42 among the stranded conductors 41 and 51. It is composed of the tip welded parts 43 and 53 exposed from the tip of 52 and welded, and the tip welded parts 43 and 53 are welded to the bus bar terminal tip 32, so that the tip welded parts 43 and 53 In the above, the conductors constituting the stranded conductors 41 and 51 can be welded to each other, and the stranded conductors 41 and 51 and the bus bar terminal tip portion 32 can be welded in a conductive manner. Thereby, the conductivity between the stranded conductors 41 and 51 and the shunt resistor 30 and the conductivity of the stranded conductors 41 and 51 can be improved.

Furthermore, the tip welding processed portions 43 and 53 are welded so as to have a width corresponding to the width L which is the width of the bus bar terminal tip portion 32, so that the tip welding is arranged with respect to the bus bar terminal tip portion 32. The processed portions 43 and 53 can be reliably positioned, and the contact area between the tip welded portions 43 and 53 and the bus bar terminal tip portion 32 can be secured as a desired contact area. Thereby, the conductivity can be surely improved.

Further, the tip welding processed portions 43 and 53 are eccentric coated electric wires that are eccentrically welded from the front-rear direction X of the coated electric wires 40 and 50, and the coated electric wires 50 that are the eccentric coated electric wires are separated from each other from the coated electric wires 40. The first coated electric wire 40 connected to the upper surface 33 which is the main surface on the upper side and the second coated electric wire 50 connected to the bottom surface 34 which is the main surface on the lower side are arranged in such an orientation. , It is possible to prevent mutual interference. Thereby, for example, it is possible to prevent the space on the upper side from being eroded by pushing up the first coated electric wire 40 to the second coated electric wire 50.

Furthermore, the first coated electric wire 40 and the second coated electric wire 50 are provided with the phosphorus copper brazing 60 at the welded portion where the first coated electric wire 40 and the second coated electric wire 50 are welded at the tip end portion 32 of the bus bar terminal. The tip portion 32 of the bus bar terminal can be reliably welded. As a result, the conductivity between the first coated electric wire 40 and the second coated electric wire 50 and the shunt resistor 30 can be more reliably improved.

In the correspondence between the configuration of the present invention and the above-described embodiment, the post terminal corresponds to the connection terminal 10.
The bus bar terminal corresponds to the shunt resistor 30 and
The battery status detection sensation corresponds to the battery status detection device main body 2.
The first coated electric wire and the small diameter coated electric wire correspond to the first coated electric wire 40.
The second coated electric wire and the eccentric coated electric wire correspond to the second coated electric wire 50.
One main surface side corresponds to the upper surface 33,
The other main surface side corresponds to the bottom surface 34 and
The longitudinal direction corresponds to the front-back direction X,
The brazing material corresponds to phosphorus copper brazing 60,
The present invention is not limited to the configuration of the above-described embodiment, and many embodiments can be obtained.

For example, in the present embodiment, the first tip welded portion 43 and the second tip welded portion 53 are simultaneously irradiated with ultrasonic waves to be welded to the bus bar terminal tip portion 32, but the welding must not always be performed at the same time. It is not mandatory and each weld may be done separately.

Here, when the first tip welded portion 43 and the second tip welded portion 53 are welded separately to the bus bar terminal tip portion 32, the upper surface is formed by welding the bottom surface 34 and the second tip welded portion 53. Even if the phosphorus copper wax 60 attached to 33 melts, it does not fall off, and welding on the upper surface 33 side can be performed reliably.

Further, as a method of welding the first coated electric wire 40 and the second coated electric wire 50 and the tip portion 32 of the bus bar terminal, ultrasonic welding is adopted in this embodiment, but if it is welded, the welding method may be used. Instead, for example, ultrasonic welding, arc welding, resistance welding, or the like may be used.

Furthermore, the brazing material attached to the bus bar terminal tip portion 32 and the brazing material for welding the first tip welding processed portion 43 and the second tip welding processed portion 53 are the same, but they are not necessarily the same brazing material. It is not necessary, and different types of brazing materials may be used.

Although it is said that phosphorus copper brazing is used as the brazing material used for welding, any brazing material can be used as long as the first coated electric wire 40 and the second coated electric wire 50 and the bus bar terminal tip portion 32 can be welded. Often, for example, aluminum brazing or silver brazing may be used.

1 Battery condition detection sensor 10 Connection terminal 30 Shunt resistor 31 Shunt resistor 33 Top 34 Back 40 First coated wire 41 Twisted wire conductor 42 Insulation coating 43 First tip welded portion 43a First tip exposed portion 50 Second coated wire 51 Twisted conductor 52 Insulation coating 53 Second tip welded part 53a First tip exposed part 60 Phosphorus copper brazing X Front-rear direction

Claims (12)

In a battery state detection sensor that is provided with a post terminal attached to a battery post and a bus bar terminal that is electrically connected to the post terminal and has a shunt resistance to measure the characteristics of the battery.
The bus bar terminal is formed in a plate shape.
Two coated wires welded to the bus bar terminal are provided.
The covered electric wire is
A first-coated electric wire arranged and welded on one of the two main surfaces of the bus bar terminal formed in a plate shape,
A battery state detection sensor that is arranged on the other main surface side of the bus bar terminal formed in a plate shape and is composed of a welded second coated electric wire. The bus bar terminal is arranged so that one main surface is on the tip end side of the battery post and the other main surface is on the base end side of the battery post.
The battery state detection sensor according to claim 1, wherein the first coated electric wire is a small diameter coated electric wire having a smaller diameter than the second coated electric wire. The battery state detection sensor according to claim 1 or 2, wherein the two covered electric wires are arranged along the longitudinal direction of the bus bar terminal. The coated electric wire is composed of a stranded conductor, an insulating coating covering the stranded conductor, and a tip welded portion of the stranded conductor exposed from the tip of the insulating coating and welded.
The battery state detection sensor according to any one of claims 1 to 3, wherein the tip welded portion is welded to the bus bar terminal. The battery state detection sensor according to claim 4, wherein the tip welded portion is welded to a width corresponding to the width of the bus bar terminal. The covered electric wire is
The tip welded portion is an eccentric coated electric wire welded by eccentricity from the axial direction of the coated electric wire.
The battery condition detection sensor according to claim 4 or 5, wherein the eccentric coated electric wire is arranged so as to separate the two coated electric wires. The battery state detection sensor according to any one of claims 1 to 6, wherein a brazing material is provided at a welded portion where the coated electric wire is welded at the bus bar terminal. A post terminal attached to the battery post and a bus bar terminal electrically connected to the post terminal and having a shunt resistance are provided, and a coated electric wire is connected to the bus bar terminal in the battery state detection sensor that measures the characteristics of the battery. It is a method of connecting covered electric wires.
The bus bar terminal is formed in a plate shape.
The coated electric wire of one of the two coated electric wires is arranged on the main surface side of one of the two main surfaces of the bus bar terminal formed in a plate shape, and is welded to the one main surface.
A method of connecting a coated electric wire in which the other coated electric wire is arranged on the other main surface side of the bus bar terminal formed in a plate shape and welded to the other main surface. Of the coated electric wires composed of the stranded conductor and the insulating coating that covers the stranded conductor, the exposed tip portion exposed from the tip of the insulating coating is welded in advance.
The method for connecting a covered electric wire according to claim 8, wherein the welded tip exposed portion is welded to the bus bar terminal so as to be conductive. The method for connecting a covered electric wire according to claim 9, wherein the exposed tip is welded to a width corresponding to the width of the bus bar terminal. The exposed tip is eccentric from the axial direction of the covered electric wire and welded.
The method for connecting a coated electric wire according to claim 9 or 10, wherein the coated electric wire whose tip exposed portion is welded is arranged in a direction in which the two coated electric wires are separated from each other. The method for connecting a coated electric wire according to any one of claims 8 to 11, wherein a brazing material is attached to a welded portion where the coated electric wire is welded at the bus bar terminal, and then the coated electric wire is welded.

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